Photovoltaic module mounting structure

ABSTRACT

Various embodiments of mounting structures for solar photovoltaic (PV) modules and methods for constructing such mounting structures are described. A mounting structure is usable to secure PV modules in portrait orientation or landscape orientation. PV modules are secured to PV module support rails, which may be secured to purlins of a mounting structure using clamps. In some embodiments, self-adhesive grounding patches are used to establish electrical grounding paths in various embodiments of mounting structure.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. Provisional Appl. No.63/068,017 filed on Aug. 20, 2020; which is incorporated by referenceherein in its entirety.

BACKGROUND Technical Field

This disclosure relates generally to mounting structures forphotovoltaic modules.

Description of the Related Art

In order to facilitate electricity generation, solar photovoltaic (PV)modules can be mounted on various structures such as rooftops, fixedtilt ground mount structures, and active tracking structures that trackthe location of the sun. PV modules can also be mounted on carports inparking lots or on the tops of parking garages. Further, PV modules canbe mounted on structures for pedestrian walkways, bus stops, outdoortrain stations, or bike lanes. Such PV modules may be monofacial PVmodules that are configured to generate electricity from received lighton one side (i.e., the top) of the module or bifacial PV modules thatare configured to generate electricity from received light on both sides(i.e., the top and bottom) of the module.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a bottom perspective view of a dual-tilt mounting structurewith photovoltaic (PV) modules mounted in portrait orientation inaccordance with various embodiments.

FIG. 2 is a bottom perspective view of a dual-tilt mounting structurewith PV modules mounted in landscape orientation in accordance withvarious embodiments.

FIGS. 3A-3D are cutaway side views of various embodiments of mountingstructures in accordance with various embodiments.

FIGS. 4A and 4B are cutaway side views of embodiments of long spanmounting structures in accordance with various embodiments

FIG. 5A is a bottom perspective partially exploded view of the dual-tiltmounting structure with PV modules mounted in portrait orientation ofFIG. 1 in accordance with various embodiments.

FIG. 5B is a top view of a set of PV modules mounted in portraitorientation on a set of PV module support rails in accordance withvarious embodiments.

FIG. 5C is a cutaway side view of a PV module mounted in portraitorientation on a set of PV module support rails in accordance withvarious embodiments.

FIG. 5D is a sideview of a plurality of mounting structures and amounting surface with reflective coatings in accordance with variousembodiments.

FIG. 6A is a bottom perspective partially exploded view of the dual-tiltmounting structure with PV modules mounted in landscape orientation ofFIG. 2 in accordance with various embodiments.

FIG. 6B is a top view of a set of PV modules mounted in landscapeorientation on a set of PV module support rails in accordance withvarious embodiments.

FIG. 6C is a cutaway side view of two PV modules mounted in landscapeorientation on a set of PV module support rails in accordance withvarious embodiments.

FIG. 7A is an exploded top view of a portion of the dual-tilt mountingstructure of FIG. 1 with the PV modules omitted in accordance withvarious embodiments.

FIG. 7B is a top view of the dual-tilt mounting structure of FIG. 1 withthe PV modules omitted in accordance with various embodiments.

FIG. 7C is a top view of the dual-tilt mounting structure of FIG. 2 withthe PV modules omitted in accordance with various embodiments.

FIG. 8 is a bottom perspective view dual-tilt mounting structure of FIG.1 with various water management features highlighted in accordance withvarious embodiments.

FIG. 9A is a perspective view of portions of the PV module support railclamp of FIGS. 5A and 6A in accordance with various embodiments.

FIG. 9B is a perspective view of portions of an alternative PV modulesupport rail clamp in accordance with various embodiments.

FIGS. 9C, 9E, and 9G are various views of the PV module support railclamp of FIG. 9A installed with the top portion of the PV module supportrail clamp secured to an outer surface of a PV support module supportrail.

FIGS. 9D, 9F, and 9H are various views of the PV module support railclamp of FIG. 9A installed with the top portion of the PV module supportrail clamp secured to an inner surface of a PV support module supportrail.

FIGS. 10A-10C are various views of the self-adhesive grounding patch ofFIG. 7A in accordance with various embodiments.

FIG. 11 is flowchart illustrating an embodiment of a PV module supportstructure construction method in accordance with various embodiments.

FIG. 12 is flowchart illustrating an embodiment of a PV module supportstructure construction method in accordance with various embodiments.

This disclosure includes references to “one embodiment” or “anembodiment.” The appearances of the phrases “in one embodiment” or “inan embodiment” do not necessarily refer to the same embodiment.Particular features, structures, or characteristics may be combined inany suitable manner consistent with this disclosure.

Within this disclosure, different entities (which may variously bereferred to as “units,” “circuits,” other components, etc.) may bedescribed or claimed as “configured” to perform one or more tasks oroperations. This formulation—[entity] configured to [perform one or moretasks]—is used herein to refer to structure (i.e., something physical,such as an electronic circuit). More specifically, this formulation isused to indicate that this structure is arranged to perform the one ormore tasks during operation. A structure can be said to be “configuredto” perform some task even if the structure is not currently beingoperated. Thus, an entity described or recited as “configured to”perform some task refers to something physical, such as a structure thatwhen constructed implements the task (e.g., a clamp configured to coupleto a crossbeam). The term “configured to” is not intended to mean“configurable to.”

Reciting in the appended claims that a structure is “configured to”perform one or more tasks is expressly intended not to invoke 35 U.S.C.§ 112(f) for that claim element. Accordingly, none of the claims in thisapplication as filed are intended to be interpreted as havingmeans-plus-function elements. Should Applicant wish to invoke Section112(f) during prosecution, it will recite claim elements using the“means for” [performing a function] construct.

As used herein, the terms “first,” “second,” etc. are used as labels fornouns that they precede, and do not imply any type of ordering (e.g.,spatial, temporal, logical, etc.) unless specifically stated. Forexample, references to “first” and “second” purlins would not imply anordering between the two unless otherwise stated.

As used herein, the term “based on” is used to describe one or morefactors that affect a determination. This term does not foreclose thepossibility that additional factors may affect a determination. That is,a determination may be solely based on specified factors or based on thespecified factors as well as other, unspecified factors. Consider thephrase “determine A based on B.” This phrase specifies that B is afactor is used to determine A or that affects the determination of A.This phrase does not foreclose that the determination of A may also bebased on some other factor, such as C. This phrase is also intended tocover an embodiment in which A is determined based solely on B. As usedherein, the phrase “based on” is thus synonymous with the phrase “basedat least in part on.”

DETAILED DESCRIPTION

Mounting structures for solar photovoltaic (PV) modules allow PV modulesto be installed in places such as parking lots, parking garages, busstops, train stations, pedestrian walkways, and bike lanes. Suchmounting structures are configured to secure the PV modules and toelevate them several feet in the air so other activity can occurunderneath. For example, a mounting structure might secure PV modulesand provide cover for cars parked or people waiting for a busunderneath. Elevated PV modules, being relatively high off the ground,are also less likely to be shaded to the extent that PV modules mountedlower to the ground might be.

In the past, mounting structures were generally used to securemonofacial PV modules that are configured to generate electricity fromreceived light on one side (i.e., the top) of the module. Increasingly,however, there has been interest in bifacial PV modules that are able togenerate more electricity (in certain conditions) because they cangenerate electricity from received light on both sides (i.e., the topand bottom) of the module. Depending on the configuration of themodules, monofacial PV modules and bifacial PV modules may not bemounted in the same way. In some instances, monofacial PV modules may bemounted in a landscape orientation and bifacial PV modules may bemounted in a portrait orientation for any of a number of reasons. Forexample, monofacial PV modules may be internally wired such thatlandscape mounting will generate more electricity. In contrast, bifacialPV modules may be wired to be mounted in a portrait orientation.Customers might also have an aesthetic preference for the mountingorientation. For example, if a customer has a large parking lot thatalready has mounting structures with PV modules installed in a landscapeorientation, that customer might demand that additional mountingstructure be installed with PV modules oriented the same way to match.

Many PV modules have opaque (typically metal) frames around theencapsuled solar PV cells. Such opaque frames absorb light or reflect itback into space. Because bifacial PV modules are able to generateelectricity on both sides of the panel, increasing the amount of lightthat passes through the mounting structure to be potentially reflectedback towards the backside of the bifacial PV modules means thatadditional electricity may be generated. Additionally, the conditions ata mounting surface might not be uniformly flat or conditions on theground might differ from a site plan that is provided to a contractorbuilding a mounting structure for PV modules. Further, PV modules have afinite lifespan of about 20 to 30 years under normal circumstances, andcan also be damaged by falling trees or storms, and therefore might needto be replaced before the end of the useful life of the mountingstructure beneath. Moreover, a customer might initially install amounting structure with monofacial PV modules and then later upgrade tobifacial PV modules.

Mounting structures are typically made of metal such as structural steeland steel-reinforced concrete. Because PV modules mounted on a mountingstructure are high voltage electrical equipment mounted on metal high inthe air, there is a risk that voltage will build up on the mountingstructure and result in potentially dangerous discharge. Accordingly,mounting structures employ grounding devices to establish groundingpaths that flows from the frames of the PV modules, through the mountingstructure, and into the ground via grounding stakes. Such groundingdevices are typically installed late in the construction of the mountingstructure by skilled electricians.

Accordingly, the inventors identified various issues with prior mountingstructures that include, but are not limited to: (1) a mountingstructure should be able to accommodate PV modules installed inlandscape or portrait orientation, (2) a mounting structure should bedesigned such that either monofacial PV modules or bifacial PV modulesmay be installed on the mounting structure, (3) shading should bereduced and reflection of light should be increased to enable more lightto be collected by the backside of bifacial PV modules, (4) the mountingstructure should have sufficient adaptability that allows forirregularities at the construction site to be accommodated, (5) PVmodules should be able to be easily replaced after installation on themounting structure, and (6) grounding paths should be able to beestablished as the mounting structure is being built from the ground upby construction personnel and not after the PV modules are installed bymore costly electricians. In order to address these issues, theinventors propose a novel PV module mounting structure that allows forinstallation of PV modules in landscape or portrait orientation andaccommodates site irregularities, reduces shading and increasesreflected light on the backside of PV modules, allows PV modules to beeasily removed from the mounting structure, and establishes groundingpaths from the ground up during construction.

Dual-Tilt Mounting Structure with PV Modules in Portrait Orientation

FIG. 1 is a bottom perspective view of a dual-tilt mounting structure100 with photovoltaic (PV) modules 114 mounted in portrait orientation130 in accordance with various embodiments. Mounting structure 100 isinstalled over a mounting surface 102. A plurality of column foundations104 extend from the mounting surface 102 (and in embodiments, extendbelow into mounting surface 102). A plurality of columns 106 are coupledto the column foundations 104. A plurality of crossbeams 108 are coupledto the columns 106. A plurality of purlins 110 are coupled to thecrossbeams 108. In the embodiment shown in FIG. 1 , a first set ofpurlins 110 are coupled to a first end of crossbeams 108 on the left endof crossbeams 108. A second set of purlins 110 are coupled to a second,opposite end of crossbeams 108 on the right end of crossbeams 108. Afirst plurality of PV module support rails 112 are coupled to thepurlins 110. A second plurality of PV module support rails 116 arecoupled to the first plurality of PV module support rails 112. PVmodules 114 are coupled to the PV module support rails 112, 116 in afirst grid 120 and a second grid 122. PV module 114 are installed ondual-tilt mounting structure 100 in a portrait orientation 130.

In the embodiment shown in FIG. 1 , dual-tilt mounting structure 100extends along three axes. A first axis (the z-axis shown in FIGS. 1 and2 ) extends upward from mounting surface 102. Column foundation 104 andcolumns 106 lay at least in part along the first axis. A second axis(the x-axis shown in FIGS. 1 and 2 ) extends orthogonally from thesecond axis. Crossbeams 108 and PV module rails 112 lay at least in partalong the second axis. A third axis (the y-axis shown in FIGS. 1 and 2 )extends orthogonally from the second and third axes. Purlins 110 lay atleast in part along the third axis.

Mounting surface 102 may be any of a number of surfaces onto which amounting structure (e.g., mounting structure 100) is installed. In someembodiments, mounting surface 102 is a parking lot on the ground or atop level of a parking garage. In such embodiments, dual-tilt mountingstructure 100 is configured to allow cars and trucks to be installedunderneath dual-tilt mounting structure 100. In such embodiments,dual-tilt mounting structure 100 may be referred to herein as a“carport.” In other embodiments, however, dual-tilt mounting structure100 (or any mounting structure discussed herein such as mountingstructures 200, 320, 330, 340, 400, and 410) are not limited toembodiments in which the mounting structure is a carport installed overa parking lot. In various embodiments, mounting surface 102 is a streetor a sidewalk and the mounting surface is useable as cover for apedestrian walkway, bus stop, or bike lane. Alternatively, mountingsurface 102 may be a train platform and the mounting surface is usableas a cover for a train platform.

Column foundations 104 are steel-reenforced concrete pillars that extendinto mounting surface 102 in various embodiments. In some embodiments,however, column foundation 104 may be made of other materials and/or maybe secured to mounting surface 102 by fasteners such as bolts (notshown). Columns 106 are coupled to a top surface of column foundations104 by a plurality of fasteners (e.g., fasteners 310 shown in FIGS.3A-3D). In various embodiments, no column foundation 104 is present andcolumn 106 is directly fastened to mounting surface 102 (e.g.,embodiments in which mounting structure is smaller than the embodimentsshown in FIG. 1 and is not used as a carport). In various embodiments,column 106 is an I-beam, a square beam (shown in FIG. 1 ), or a tube orother suitable shape. In various embodiments, column 106 is made ofmetal (such as stainless steel) or an electrically conductive compositematerial. In various embodiments, column 106 includes a first flat plateon the bottom with openings configured to accept fasteners to couple thecolumn 106 to a column foundation 104 (or mounting surface 102) and asecond flat plate on the top with openings configured to acceptfasteners to couple the column 106 to crossbeam 108. In otherembodiments, the top of column 106 is saddle-shaped and partiallysurrounds crossbeam 108. The coupling of column 106 to crossbeam 108 isdiscussed in additional detail in reference to FIG. 7A.

Crossbeams 108 are coupled to the top ends of columns 106. In variousembodiments, crossbeams 108 are I-beams, although other suitable shapesmay be used (e.g., a square beam). A first set of purlins 110 is coupledto first end of crossbeams 108 and a second set of purlins 110 iscoupled to second end of crossbeams 108. In various embodiments,crossbeam 108 is made of metal (such as stainless steel) or anelectrically conductive composite material. The coupling of crossbeam108 to purlins 110 is discussed in additional detail in reference toFIG. 7A.

In various embodiments, purlins 110 are coupled to crossbeams 108 at thelateral sides of crossbeams 108 as shown in FIG. 1 (e.g., fasteners 706and brackets 704 as discussed in additional detail in reference to FIG.7A). In various other embodiments, however, purlins 110 could insteadrest on top of crossbeams 108 and be coupled to the top of crossbeams108 by fasteners that extend downward (i.e., along the first axis)through purlins 110 and into crossbeams 108. In various embodiments,purlins 110 are I-beams (as shown in FIGS. 1 and 2 ) but in otherembodiments, purlins 110 may be T-beams or square beams. In variousembodiments, purlins 110 define a top flange upon which PV modulesupport rails 112 lie and a bottom surface that faces mounting surface102. In various embodiments, bottom surface defines a flange (e.g., ifpurlin 110 is an I-beam). PV module support rails 112 are coupled topurlins 110 (e.g., by clamps 500 shown in FIGS. 5A and 6A). The couplingof purlins 110 to PV module support rails 112 is discussed in additionaldetail in reference to FIGS. 5A, 6B, and 7A.

In the dual-tilt embodiment shown in FIG. 1 (and in FIG. 2 ) a first setof PV module support rails 112 are coupled to purlins 110 and a secondset of PV module support rails 116 are coupled to the first set of PVmodule support rails 112. In the embodiment shown in FIG. 1 , the PVmodule support rails 112 and 116 are C-shaped beams that define a topsurface, an opposing bottom surface, and a middle surface disposedbetween the top surface and the bottom surface. In various embodiments,PV module support rails 112, 116 are made of metal (such as stainlesssteel) or an electrically conductive composite material. As discussed infurther detail in reference to FIGS. 5A and 6A, the bottom surface of PVmodule support rails 112 rests on purlins 110. In various embodiments, aclamp (e.g., clamp 500 shown in FIGS. 5A and 6A) is used to couple themiddle surface of PV module support rails 112 to the purlins 110. Invarious embodiments, PV module support rails 116 have a similar (oridentical) cross-section to PV module support rails 112, but instead ofresting on purlins 110, PV module support rails 116 are coupled to PVmodule support rails 112 (e.g., by bracket 702 shown in FIG. 7A) and arecantilevered over mounting surface 102. PV modules 114 are coupled to PVmodule support rails 112 and PV module support rails 116 (e.g., byfasteners 510 shown in FIGS. 5A and 5B). In various embodiments,blocking rails 118 are coupled to the ends of PV module support rails112, 116 to provide lateral support for PV module support rails 112,116.

The arrangement of PV module support rails 112 (and in dual-tiltembodiments the PV module support rails 116) relative to the purlins 110varies depending on the size of the PV modules 114 and the orientation(i.e., landscape orientation 202 shown in FIG. 2 versus portraitorientation 130). As discussed in further detail in reference to FIGS.5A and 6A, the spacing of PV module support rails 112, 116 relative toeach other may differ according to the size and orientation of PVmodules 114. In various embodiments in which PV modules 114 areinstalled in portrait orientation 130, PV module support rails 112, 116face the same direction. In various embodiments in which PV modules 114are installed in landscape orientation, however, pairs of PV modulesupport rails 112, 116 may face each other (e.g., PV module supportrails 112A and 112B shown in FIG. 6A). In various embodiments, blockingrails 118 are disposed between every PV module support rail 112, 116,but in other embodiments blocking rails are only disposed betweenopposing sets of PV module support rails 112, 116 (e.g., as shown inFIG. 6A).

In the embodiment shown in FIG. 1 , PV modules 114 are disposed inportrait orientation 130 in a first grid 120 having columns extendingalong the second axis and rows extending along the third axis. As shownin additional detail in FIGS. 5A and 5B, adjacent columns of PV modules114 in first grid 120 share a PV module support rail 112 between them.Thus, if a first set of PV modules 114 are in a first column and secondset of PV modules 114 are in an adjacent second column, they are securedto a top surface of a same PV module support rail 112 disposed betweenthe first column and the second column. Similarly, PV modules 114 indual-tilt embodiments like dual-tilt mounting structure 100 are disposedin portrait orientation 130 in a second grid 122 having columnsextending along the second axis and rows extending along the third axis.In various embodiments, adjacent columns of PV modules 114 in secondgrid 122 share a PV module support rail 116 between them in the samefashion as first grid 120. In various embodiments, the columns of firstgrid 120 and second grid 122 are aligned and the rows of the first gridand the second grid are parallel. As shown in FIG. 1 , first grid 120and second grid 122 are disposed on planes that intersect. In variousembodiments, first grid 120 lies at between a 2- and 15-degree anglerelative to mounting surface 102 and second grid 122 lies at between a−2- and −5-degree angle relative to mounting surface 102.

PV modules 114 may be any of a number of rectangular-shaped PV modules.In various embodiments, PV modules 114 are surrounded by frames made ofmetal (e.g., steel, aluminum, etc.), composite, or plastic. In suchembodiments, PV modules 114 are secured to PV module support rails 112by fasteners that pass through the frames of PV modules 114 and PVmodule support rails 112 (e.g., as shown in FIGS. 5A and 6A) or byclamps that couple to the top side of PV modules 114 and are secured toPV module support rails 112. In various embodiments, such frames areopaque. In some embodiments, however, PV modules 114 are frameless(e.g., frameless bifacial PV modules) and are mounted to PV modulesupport rails 112 by adhesives or clamps that couple to the top side ofPV modules 114 and are secured to PV module support rails 112. Asdiscussed herein, PV modules 114 may be mounted in portrait orientation130 (i.e., the long side of the PV module 114 is parallel to PV modulesupport rails 112 and crossbeams 108) or in landscape orientation 202(i.e., the long side of the PV module 114 is perpendicular to PV modulesupport rails 112 as shown in FIG. 2 .

In various embodiments, PV modules 114 are monofacial modules withphotovoltaic cells (e.g., monocrystalline silicon photovoltaic cells,polycrystalline silicon photovoltaic cells) arranged on an opaquebacking sheet and surrounded by an encapsulant. The photovoltaic cellsin a monofacial PV module 114 may be front-contact photovoltaic cellsarranged individually or in a shingled arrangement in which adjacentphotovoltaic cells overlap. Alternatively, photovoltaic cells in amonofacial PV module 114 may be interdigitated back contact photovoltaiccells. In other embodiments, PV modules 114 are monofacial thin-filmphotovoltaic modules. In other embodiments, PV modules 114 are bifacialmodules with photovoltaic cells (e.g., monocrystalline siliconphotovoltaic cells, polycrystalline silicon photovoltaic cells) arrangedon a transparent backing sheet and surrounded by an encapsulant. In suchembodiments, the photovoltaic cells of a bifacial PV module 114 areconfigured to generate electricity that is received from the sundirectly on the top surface of the PV module 114 that faces the sun andindirectly (i.e., reflected light, ambient light) on the bottom surfaceof the PV module that faces mounting surface 102. It will be understoodthat light that is received by a solar cell of a PV module 114 causeselectricity to be generated, light that passes through a clearencapsulant continues on towards mounting surface 102, and light thatimpacts an opaque frame or encapsulant is absorbed or reflected.

Thus, in embodiments such as FIG. 1 , PV modules 114 are disposed inportrait orientation 130 with the long edges of the frames of PV modules114 lying on top of PV module support rails 112 and 116. In embodimentsin which PV modules 114 are bifacial, this means that fewer shadows arecast on the back side of the bifacial PV modules 114 by structural steelsuch as PV module support rails 112 and 116, which would prevent acertain amount of reflected or ambident light from reaching the backside of the bifacial PV modules 114. For example, if a bifacial PVmodule 114 was arranged in landscape orientation 202 (e.g., as shown inFIG. 2 and FIG. 6B for example) any light reflected from the mountingsurface 102 onto the bottom surface of the PV module support rails 112and 116 that intersect with the long edges of the frames of PV modules114 would not reach the backside of the solar cells of the PV modules114.

Dual-Tilt Mounting Structure with PV Modules in Landscape Orientation

FIG. 2 is a bottom perspective view of a dual-tilt mounting structure200 with PV modules 114 mounted in landscape orientation 202 inaccordance with various embodiments. In various embodiments, themounting surface 102, column foundations 104, columns 106, crossbeams108, and purlins 110 are identical to those described above in referenceto FIG. 1 . Indeed, in various embodiments, a dual-tilt mountingstructure 200 may be reconfigured to become a dual-tilt mountingstructure 100 shown in FIG. 1 by reconfiguring the arrangement of PVmodule support rails 112 and 116, blocking rails 118, and PV modules114. In various embodiments, the PV modules 114 installed on dual-tiltmounting structure 200 are installed in landscape orientation 202. Invarious embodiments, such PV modules 114 are monofacial PV modules.Accordingly, in various instances the monofacial PV modules 114 may beremoved from dual-tilt mounting structure 200, the PV module supportrails 112 and 116 and blocking rails 118 repositioned, and bifacial PVmodules 114 installed in portrait orientation 130. Accordingly, the samecolumn foundations 104, columns 106, crossbeams 108, purlins 110, PVmodule support rails 112 and 116, blocking rails 118, and PV modules 114are usable to construct a dual-tilt mounting structure 200 with PVmodules 114 mounted in landscape orientation 202 or a dual-tilt mountingstructure 100 with PV modules 114 mounted in portrait orientation 130.

As discussed in additional detail in reference to FIGS. 6A and 6B, invarious embodiments, the same PV module support rails 112 and 116 andblocking rails 118 may be used to construct dual-tilt mounting structure200. In various embodiments, however, rather than all of the PV modulesupport rails 112 and 116 facing the same direction, pairs of PV modulesupport rails 112 and 116 may face each other. Additionally, blockingrails 118 may be installed between pair of facing PV module supportrails 112 and 116 and not between PV module support rails 112 and 116that face away from each other. This configuration can be seen moreclearly in FIG. 6A below.

In contrast to portrait orientation 130 in which the long sides of theframes of the PV modules 114 lay on top of PV module support rails 112and 116, in landscape orientation 202, the long sides of the frames ofPV modules 114 are perpendicular to PV module support rails 112 and 116.As with first grid 120 and second grid 122 of FIG. 1 , thelandscape-oriented PV module 114 in FIG. 2 are arranged in a first grid204 and a second grid 206 in which columns for first grid 204 arealigned with columns of second grid 206 and first grid 204 and secondgrid 206 define planes that intersect.

As shown in FIG. 6B, landscape orientation 202 results in shadows beingcast on the backside of the PV modules 114, but if the PV modules 114are monofacial, this will not affect power generation. Moreover,depending on the shading conditions at a particular site (e.g., due totrees or tall buildings) a landscape orientation 202 may result in morepower generation than portrait orientation 130, even for bifacial PVmodules 114. Accordingly, the mounting structures described herein allowfor flexibility in both design and construction of the mountingstructure without having to use different sets of parts.

Side Views of Various Single-Tilt and Dual-Tilt Mounting Structures

FIGS. 3A-3D are cutaway side views of various embodiments of mountingstructures in accordance with various embodiments. FIGS. 4A and 4B arecutaway side views of embodiments of long span mounting structures inaccordance with various embodiments. In various embodiments, each of themounting structure depicted in FIGS. 3A-3D and 4A-4B are constructedover a mounting surface 102 and include arrangements of columnfoundation 104 and columns 106 as described above.

Referring individually to FIG. 3A, a side view of a dual-tilt mountingstructure 100 is shown (although in various embodiments a side view ofdual-tilt mounting structure 200 would also look like FIG. 3A). Inaddition to mounting surface 102, column foundation 104, columns 106,crossbeams 108, purlins 110, and PV module support rails 112 and 116discussed above in reference to FIGS. 1 and 2 , FIG. 3A identifiesvarious water management features. A gutter 302 is disposed beneath thejunction of PV module support rails 112 and 116 and collects water thatflows across first grid 120 and second grid 122. Gutter 302 drainsthrough pipe 304 and into a downspout 306 in column 106. In variousembodiments, downspout 306 discharges water onto mounting surface 102 orinto a cistern installed on mounting surface 102 (not shown), but inother embodiments, downspout 306 drains to pipes beneath mountingsurface 102 (e.g., to a drainage system of a parking garage, to arainwater sewer, to an underground cistern). As shown in FIG. 3A, columnfoundation 104 is partially cut away, showing fasteners 310 that areburied in column foundation 104 and are received by correspondingopenings on a flat bottom portion of column 106. Nuts are used to securecolumn 106 to fasteners 310 in various embodiments.

FIG. 3A also includes various dimensions A-E. As shown in FIG. 3A, thelongest dimension is D, the span of the top of mounting structure 100.In various embodiments, D is 41 feet, 10 inches (approximately 12.75meters). Dimension E, the extent to which column foundations 104 extendabove mounting surface 102 is between 2.5 feet (approximately 0.76meters) and 4 feet (approximately 1.22 meters). Dimensions B and C arebased on Dimension A, which is the minimum clearance under mountingstructure 100. In some embodiments, Dimension A is 11 feet(approximately 3.35 meter) and Dimension B is 14 feet, 4 inches(approximately 4.37 meters) and Dimension C is 18 feet, 5 inches(approximately 5.61 meters). In other embodiments, Dimension A is 13feet, 6 inches (approximately 4.11 meters) and Dimension B is 16 feet,10 inches (approximately 5.13 meters) and Dimension C is 20 feet, 11inches (approximately 6.38 meters). It will be understood, however, thatthese Dimensions A-E may vary from these numbers (e.g., by 5%, 10%,etc.) and may be changed based on customer requirements (e.g., DimensionA defines a higher minimum clearance for larger vehicles). Further, themounting structure 100 shown in FIG. 3A is a carport, and the DimensionsA-E may be reduced for applications requiring shorter spans and/orsmaller minimum clearances.

Referring now to FIG. 3B, a single-tilt mounting structure 320 is shown.In the single-tilt mounting structure 320, no PV module support rails116 are present, and PV module support rails 112 are longer.Additionally, the water management features of FIG. 3A are not present.In FIG. 3B, PV modules 114 are arranged in a single grid 322. FIG. 3Balso includes various dimensions A-E. As shown in FIG. 3B, the longestdimension is D, the span of the top of mounting structure 320. Invarious embodiments, D is 41 feet, 9 inches (approximately 12.72meters). Dimension E, the extent to which column foundations 104 extendabove mounting surface 102 is between 2.5 feet (approximately 0.76meters) and 4 feet (approximately 1.22 meters). Dimensions B and C arebased on Dimension A, which is the minimum clearance under mountingstructure 100. In some embodiments, Dimension A is 11 feet(approximately 3.35 meter) and Dimension B is 12 feet, 4 inches(approximately 3.76 meters) and Dimension C is 17 feet, 8 inches(approximately 5.38 meters). In other embodiments, Dimension A is 13feet, 6 inches (approximately 4.11 meters) and Dimension B is 14 feet,10 inches (approximately 4.52 meters) and Dimension C is 20 feet, 2inches (approximately 6.15 meters). It will be understood, however, thatthese Dimensions A-E may vary from these numbers (e.g., by 5%, 10%,etc.) and may be changed based on customer requirements (e.g., DimensionA defines a higher minimum clearance for larger vehicles). Further, themounting structure 320 shown in FIG. 3B is a carport, and the DimensionsA-E may be reduced for applications requiring shorter spans and/orsmaller minimum clearances.

Referring now to FIG. 3C, a shorter span dual-tilt mounting structure330 is shown. In shorter span dual-tilt mounting structure 330,Dimension D′ is shorter than Dimension D in FIG. 3A and Dimension C′ isshorter than Dimension C in FIG. 3A. Similarly, the crossbeam 332 isshorter than crossbeam 108. Referring now to FIG. 3D, a shorter spansingle-tilt mounting structure 340 is shown. In shorter span single-tiltmounting structure 340, Dimension D′ is shorter than Dimension D in FIG.3B and Dimension C′ is shorter than Dimension C in FIG. 3B. Similarly,the crossbeam 332 is shorter than crossbeam 108. In both shorter spandual-tilt mounting structure 330 and shorter span single-tilt mountingstructure 340 PV module support rails 112 are shorter as well.

Referring now to FIGS. 4A and 4B, a long span dual-tilt mountingstructure 400 and a long span single-tilt mounting structure 410 areshown, respectively. In mounting structures 400 and 410, crossbeams 402may be longer than crossbeams 108 and are connected to two sets ofcolumn foundations 104 and columns 106 and PV module support rails 112may be longer. In some embodiments, crossbeams 402 and PV module supportrails 112 in long span mounting structures may be comprised of multiplecrossbeams 402 or PV module support rails 112 that are coupled togetherend-to-end.

PV Modules Mounted in Portrait Orientation

FIGS. 5A-5C relate to embodiments in which PV modules 224 are mounted inportrait orientation 130. FIG. 5D relates to reflected light and relatesto bifacial PV modules, which are mounted in portrait orientation 130 insome embodiments, but may be mounted in landscape orientation 202 aswell. Referring now to FIG. 5A, a bottom perspective partially explodedview of the dual-tilt mounting structure 100 with PV modules 114 mountedin portrait orientation 130 is shown. As discussed herein, though, themounting of PV modules 114 in portrait orientation 130 is not limited tomounting structure 100 and can be used on the single-tilt, shorter span,and/or longer span embodiments discussed above.

In FIG. 5A, a set of PV module support rails 112 and 116, PV modules114, and blocking rails 118 are exploded of off purlins 110. Clamps 500and fasteners 510 and 512 are also shown. As shown in FIG. 5A, clamps500 are used to secure PV module support rails 112 to purlins 110,fasteners 510 are used to secure PV modules 114 to PV module supportrails 112 and 116, and fasteners are used to secure blocking rails 118to PV modules 114.

As shown in FIG. 5A and discussed previously, PV module support rails112 and 116 are C beams in various embodiments. As shown in FIG. 5A, alateral side of the C beam faces the viewer and the open side of the Cbeam faces away from the viewer. PV module support rails 112 and 116include a bottom surface that is coupled to purlins 110. The top surfaceof PV module support rails 112 and 116 define a plurality of openingsconfigured to accept fasteners 510 to secure PV modules 114 to PV modulesupport rails 112 and 116. As shown in FIG. 5A, fasteners 510 passthrough the long side of the frames of PV modules 114. In variousembodiments, fasteners 510 include components that establish anelectrical grounding path between PV modules 114 and PV module supportrails 112 and 116. Such components may include grounding washers thatbreach coatings (e.g., paint, reflective coatings 532 discussed inconnection to FIG. 5D) to enable the grounding path to be established.Similarly, fasteners 512 may also include similar components thatestablish and electrical grounding path between PV modules 114 andblocking rails 118.

As shown in FIG. 5A, clamps 500 couple PV module support rails 112 topurlins 110. As shown in FIG. 5A, clamps 500 include a top portion 502and one or more bottom portions 504. In various embodiments, topportions 502 are fastened to PV module support rails 112 and bottomportions 504 are coupled to purlins 110. As discussed in additionaldetail in reference to FIGS. 9A-9H, clamps 500 are not secured topurlins 110 by fasteners that pass through purlins 110 or by welding. Invarious embodiments, the top flange of purlins 110 do not define anyopenings at all. Instead, clamps 500 pinch a top flange of purlin 110and are held by tension on fasteners that pass through top portions 502and bottom portions 504. In such embodiments, the structural integrityof purlins 110 is not diminished by openings. Similarly, because clamps500 attach PV module support rails 112 to purlins 110 by pinching thetop flange and without fasteners having to pass through purlins 110,there is greater flexibility on where PV module support rails 112 can beattached. This allows for the variable spacing of PV module supportrails 112 that is used for portrait orientation 130 mounting andlandscape orientation 202 mounting without having to modify purlins 110.This avoids construction crews having to drill holes in purlins 110 inthe field, which is difficult to accomplish properly, and also avoidsthe manufacturer of purlins 110 from having to pre-drill holes for bothorientations. Additionally, this flexibility also allows for variationsat the construction site to be mitigated (e.g., irregular spacing ofcolumns 106 due to obstacles on or beneath mounting surface 102).

Similarly, because PV module support rails 112 are coupled to purlins110 by clamps 500 and not weld points or fasteners, assembly anddisassembly of the mounting structure is simplified. Columns of PVmodules 114 may be removed together by disengaging clamps 500 andlifting PV module support rails 112 and 116 and PV modules 114 off ofthe mounting structure. Similarly, PV modules 114 may be attached to PVmodule support rails 112 and 116 on the ground and then a subassembly ofPV module support rails 112 and 116 and PV modules 114 may be positionedon top of the mounting structure and secured using clamps 500. This maysimplify initial construction, as well as enabling PV modules 114 to bereplaced (e.g., replacing monofacial PV modules 114 with bifacial PVmodules 114). As discussed in additional detail below in FIGS. 7A and9A-9F, clamps 500 aid in establishing an electrical grounding pathbetween PV module support rails 112 and purlins 110.

FIG. 5B is a top view of a set of PV modules 114 mounted in portraitorientation 130 on a set of three PV module support rails 112 and 116 inaccordance with various embodiments. In FIG. 5B, purlins 110, PV modulesupport rails 112 and 116, and gutter 302 are shown in dashed linesbecause they are obscured by PV modules 114. As can be seen on FIG. 5B,the long sides of PV modules 114 are parallel to and overlap PV modulessupport rails 112 and 116. In the embodiment shown in FIG. 5B, the longsides of frames of PV modules 114 lay on top of PV module support rails112 and 116. Accordingly, PV module support rails 112 and 116 do notcause shadows across middle of the backside of PV modules 114, whichincrease the amount of reflected light 522 and ambient light 524 thatcan reach the back side of the PV module 114.

FIG. 5C is a cutaway side view of a PV module 114 mounted in portraitorientation 130 on a set of PV module support rails 112 in accordancewith various embodiments. As shown in FIG. 5C, direct light 520 isreceived by the top of PV module 114 and reflected light 522 and ambientlight 524 are received by the back of PV module 114. As shown in FIG.5C, very little reflected light 522 and ambient light 524 is blocked byPV module support rails 112 because the PV module support rails 112 areparallel to and overlap with the long edges of the frames of PV modules114. In embodiments in which PV module 114 is a bifacial PV module, thisincrease the amount of energy that can be generated.

FIG. 5D is a side view of a plurality of mounting structures 100 and amounting surface 102 with reflective coatings 532 and 530, respectivelyin accordance with various embodiments. Direct light 520 shines from thesun to the tops of PV modules 114. Light that shines between mountingstructures 100 is reflected by the reflective coating on mountingsurface 102 as reflected light 522 and bounces back up to the backsideof PV modules 114. Similarly, ambient light 524 bounces off ofreflective coatings 530 and 532, and some of it reaches the back side ofPV modules 114 as well. Additionally, in embodiments in which PV modules114 have transparent back sheets and encapsulant, light that passesthrough the PV modules 114 can also bounce off of reflective coatings530 and 532 reach the back side of PV modules 114.

In various embodiments, reflective coatings 530 for mounting surfaces102 have reflectance values that range from 60% for light-coloredcoatings to 30% for dark-colored coating. In embodiments in whichmounting surface 102 is concrete or asphalt, reflective coating 530 isformulated accordingly to adhere to the mounting surface 102. Similarly,reflective coatings 532 have reflectance values that range from 60% forlight-colored coatings to 30% for dark-colored coating in variousembodiments. As discussed above, the structural components of themounting structure are made of metal of composite in variousembodiments, and reflective coating 532 is formulated accordingly toadhere. Reflective coatings 530 and/or 532 may include materials such asspheres or flakes of materials like glass, glitter, or crystal thatimpart a reflective quality. In various embodiments, the columns 106,crossbeams 108, purlins 110, and PV module support rails 112 and 116 maybe coated in reflective coating 532 during manufacturing, but in otherembodiments may be painted in the field during construction. Similarly,mounting surface 102 and column foundations 104 may be painted withreflective coating 530 during construction of the mounting structure. Invarious embodiments, substantially all (e.g., 95% or more) of themounting surface beneath and between mounting structures is painted withreflective coating 530 to maximize the amount of reflected light 522 andambient light 524.

PV Modules Mounted in Landscape Orientation

FIGS. 6A-6C relate to embodiments in which PV modules 224 are mounted inlandscape orientation 202. Referring now to FIG. 6A, a bottomperspective partially exploded view of the dual-tilt mounting structure200 with PV modules 114 mounted in landscape orientation 202 is shown.As discussed herein, though, the mounting of PV modules 114 in landscapeorientation 202 is not limited to mounting structure 200 and can be usedon the single-tilt, shorter span, and/or longer span embodimentsdiscussed above.

In FIG. 6A, a set of PV module support rails 112 and 116, PV modules114, and blocking rails 118 are exploded of off purlins 110. Clamps 500and fasteners 510 and 512 are also shown. As shown in FIG. 6A, clamps500 are used to secure PV module support rails 112 to purlins 110,fasteners 510 are used to secure PV modules 114 to PV module supportrails 112 and 116, and fasteners are used to secure blocking rails 118to PV modules 114.

As shown in FIG. 6A and discussed previously, PV module support rails112 and 116 are C beams in various embodiments. In contrast to FIG. 5A,in FIG. 6A, different sets of PV module support rails 112 and 116 areoriented differently. With PV module support rails 112A and 116A, alateral side of the C beam faces the viewer and the open side of the Cbeam faces away from the viewer. With PV module support rails 112B and116B, a lateral side of the C beam faces away from the viewer and theopen side of the C beam faces the viewer. Thus, the open sides of the PVmodule support rails 112A and 116A shown exploded off purlins 110 facethe open sides of PV module support rails 112B and 116B exploded off ofpurlins 110. Blocking rails 118 are disposed between the open sides ofthe PV module support rails 112A and 116A and PV module support rails112B and 116B. In contrast to FIG. 5A, however, blocking rails 118 arenot present between each PV module support rail 112 and 116. As shown inFIG. 6A, blocking rails 118, PV module support rails 112A and 116B, andPV module support rails 112B and 116B form a box, and PV modules 114 arecoupled on top of the box by fasteners 510 and 512. The top surface ofPV module support rails 112A, 11B and 116A, 116B define a plurality ofopenings configured to accept fasteners 510 to secure PV modules 114 toPV module support rails 112A, 112B and 116A, 116B. In contrast to FIG.5A, in FIG. 6A, fasteners 510 pass through the short side of the framesof PV modules 114. In various embodiments, fasteners 510 includescomponents that establish an electrical grounding path between PVmodules 114 and PV module support rails 112A, 112B and 116A, 116B. Suchcomponents may include grounding washers that breach coatings (e.g.,paint, reflective coatings 532 discussed in connection to FIG. 5D) toenable the grounding path to be established. Similarly, fasteners 512may also include similar components that establish and electricalgrounding path between PV modules 114 and blocking rails 118.

As with FIG. 5A, clamps 500 attach PV module support rails 112A, 112B topurlins 110 without fasteners passing though purlins 110 or by weldpoints. Accordingly, an entire box of blocking rails 118, PV modulesupport rails 112A and 116B, and PV module support rails 112B and 116Bmay be assembled on the ground, and PV modules 114 secured to PV modulesupport rails 112A, 112B and 116A, 116B. Then, the entire subassemblymay be lifted onto mounting structure 200 and secured with clamps 500.To remove and replace the PV modules, this operation would just need tobe done in reverse.

FIG. 6B is a top view of a set of PV modules 114 mounted in landscapeorientation 202 on a set of PV module support rails 112A, 112B, 116A,116B in accordance with various embodiments. In FIG. 6B, purlins 110, PVmodule support rails 112A, 112B, 116A, and 116B, and gutter 302 areshown in dashed lines because they are obscured by PV modules 114.Additionally, a wire tray 600 is shown in dashed lines. Variousembodiments of mounting structure 100, 200, etc. have wire trays 600that are configured to support electrical wires connected to the PVmodules 114 in various embodiments. As shown in FIG. 6B, PV modulesupport rails 112A, 112B, 116A, and 116B cast shadows on the back sideof PV modules 114. In embodiments with bifacial PV modules 114, suchshadows might reduce power generation, but in embodiments withmonofacial PV modules 114, shadows on the back of PV modules 114 willhave little to no effect on power generation.

FIG. 6C is a cutaway side view of two monofacial PV modules 114 mountedin landscape orientation 202 on a set of PV module support rails 112Aand 112B in accordance with various embodiments. In the embodiment shownin FIG. 6C, only direct light 520 is shown because the monofacial PVmodules 114 only generate electricity on the top side.

Structural Support Components, Electrical Grounding, and WaterManagement Features of Various Mounting Structures

FIGS. 7A-7C show different views of mounting structures with the PVmodules 114 removed and focus on the “structural support components” ofthe mounting structures. As discussed here, the “structural supportcomponents” refers to the column foundation 104, columns 106, crossbeams108, purlins 110, PV module support rails 112 and 116, and blockingrails 118 as well as the various fasteners and brackets that are used tocouple these components together. As discussed above, in variousembodiments, after column foundations 104 are installed in mountingsurface 102, mounting structures described herein may be assembled usingonly fasteners, brackets, and clamps 500 and without any welding.

FIG. 7A is an exploded top view of a portion of dual-tilt mountingstructure 100 with the PV modules 114 omitted in accordance with variousembodiments. Column 106 is connected to crossbeam 108 by a plurality offasteners 708 (four are shown in FIG. 7A but more or fewer could beused) that pass through a flat top portion 709 of column 106. Crossbeam108 includes a reinforced portion 710 that is configured to receivefasteners 708 (e.g., with female screw thread installed in reinforcedportion 710). In various embodiments, fasteners 708 are male threadedscrews or bolts. Reinforced portion 710 is thicker than other portionsof crossbeam 108.

Crossbeam 108 is coupled to purlins 110 using a pair of brackets 704. Inthe embodiment shown in FIG. 7A, brackets 704 are L-shaped brackets thatare configured to receive a plurality of fasteners 706 on both sides ofthe L. While four fasteners 706 are shown in FIG. 7A, more or fewerfasteners could be used in various embodiments. In some embodiments,fasteners 706 pass though brackets 704 and into corresponding femalethreaded components embedded in crossbeam 108 and/or purlin 110. Inother embodiments holes are drilled through crossbeam 108 and/or purlin110 (either during manufacture or in the field) and fasteners aresecured using nuts on the other side of crossbeam 108 and/or purlin 110.In various embodiments, fasteners 706 are male threaded screws or bolts.Thus, in various embodiments purlins 110 are coupled to side surfaces ofthe crossbeams 108 (i.e., as opposed to resting on top of the crossbeams108 and being coupled to top flange 712). In various embodimentscrossbeam 108 includes a top flange 712 with helps support the weight ofPV module support rails 112 and PV modules 114, provides an attachmentsurface for clamp 500, and provides lateral support along the length ofcrossbeam 108. In various embodiments, crossbeam 108 defines a cutout718 that is useable to run wires (e.g., wires for lighting installed inmounting structure 100, wires connected to PV modules 114) throughmounting structure. In some embodiments, crossbeam 108 is coped (e.g.,has a notch) such that the middle portion of the crossbeam has clearanceto fit in a smaller middle section of purlin 110.

Purlins 110 are coupled to the PV module support rails 112 by clamps 500that couple to top flange 740 of purlins 110 as discussed previously andin further detail in reference to FIGS. 9A-9H. Purlins 110 define aweight-reduction cutout 742 at the ends of purlins 110 in variousembodiments.

As discussed previously, in various embodiments PV module support rails112 and 116 are C beams. In such embodiments, PV module support rails112 and 116 define a top surface 720, an intermediate surface 722, and abottom surface 724. In such embodiments, top surface 720 define a seriesof holes (e.g., threaded holes, round and slotted punches) that areconfigured to receive fasteners 510. In various embodiments, such holesare formed during manufacturing, and the top surface 720 of PV modulesupport rails 112 and 116 includes holes usable to accept fasteners 510to couple PV modules 114 in portrait orientation 130 or landscapeorientation 202 (i.e., top surface 720 defines sets of holes for bothorientations and only one set is used). Intermediate surface 722 alsodefines sets of holes configured to accept fasteners (e.g., fasteners940 shown in FIG. 9C) to couple top portion 502 of clamp 500 to theintermediate surface 722. Bottom surface 724 is configured to lie on topflange 740 when PV module support rails 112 are installed. In dual-tiltembodiments, PV module support rails 112 and 116 define holes 728 thatare configured to receive fasteners that pass through bracket 702 tosecure PV module support rails 116 to PV module support rails 112. Invarious embodiments, bracket 702 defines four holes: the top two holesare configured to receive fasteners that are received by holes 728 andthe bottom two holes are configured to receive fasteners to securegutter 302 (not shown in FIG. 7A) to bracket 702. Blocking rails 118define a pair of holes 730 that are configured to receive fasteners thatpass through PV module support rails 112 and 116 and into holes 730 tosecure blocking rails 118 between pairs of PV module support rails 112and 116.

In various embodiments, electrical grounding is facilitated byself-adhesive grounding patches 700 that are disposed between variousstructural support components. A self-adhesive grounding patch 700 isdisposed between column 106 and crossbeam 108, and when fasteners 708are tightened, the self-adhesive grounding patch 700 breaks throughcoatings (e.g., paint, anodization, or oxidation) on column 106 andcrossbeam 108 and establishes an electrical grounding path. Similarly,self-adhesive grounding patches 700 are disposed between crossbeams 108and purlins 110 such that when crossbeams 108 and purlins 110 arecoupled using bracket 704 and fasteners 706, self-adhesive groundingpatches 700 breaks through coatings (e.g., paint, anodization, oroxidation) on crossbeam 108 and purlins 110 and establishes anelectrical grounding path. In various embodiments, self-adhesivegrounding patches 700 are disposed between top portion 502 of clamp 500and PV module support rails 112 such that self-adhesive groundingpatches 700 breaks through coatings (e.g., paint, anodization, oroxidation) on PV module support rails 112 and clamp 500 and establishesan electrical grounding path. In some embodiments discussed inadditional detail in references to FIGS. 9A-9H, bottom portion 504 isable to establish a grounding path between clamp 500 and purlin 110. Inother embodiments, however, another set of self-adhesive groundingpatches 700 are disposed between bottom portion 504 and purlin 110 toestablish the grounding path. Finally, in some embodiments,self-adhesive grounding patches 700 are disposed between brackets 702and PV module support rails 112 and/or 116. Accordingly, though the useof PV module support rails 112 and/or clamps 500, an electricalgrounding path can be established between columns 106, crossbeams 108,purlins 110, and PV module support rails 112 and 116 as the structuralsupport components are installed from the ground up. This may allowmounting structures as described herein to be grounded as it is beingassembled and not after the PV modules 114 have been installed. Thisapproach may reduce the risk of electrical shocks prior to groundingpaths being established and allow non-electricians to establish thegrounding path, which may subsequently be approved by electricians atlower labor cost.

FIG. 7B is a top view of the dual-tilt mounting structure 100 with thePV modules 114 omitted. Similarly, FIG. 7C is a top view of thedual-tilt mounting structure 200 with the PV modules 114 omitted. Asshown in both FIGS. 7B and 7C, with both dual-tilt mounting structure100 and dual-tilt mounting structure 200, column foundation 104 andcolumns 106 may be installed at the mounting surface 102 in a rangelabeled G. In various embodiments, this range can be about 3 feet(approximate 0.91 meters), with the column foundation 104 and columns106 able to be installed anywhere within that 3-foot range. Moreover,column foundation 104 and columns 106 are separated by range F, whichmay range up to 36 feet (approximately 10.97 meters) in variousembodiments. Thus, a first column foundation 104 and first column 106may be 36 feet from a second column foundation 104 and second column106, but a third column foundation 104 and third column 106 are only 34feet from the second column foundation 104 and second column 106.Accordingly, column foundation 104 and columns 106 may be irregularlyspaced apart on mounting surface 102 to, for example, work aroundunexpected site conditions that were not known prior to installation.Additionally, referring to FIG. 7C, gaps 750 can be seen showing placesin which blocking rails 118 are not installed between boxes of blockingrails 118, PV module support rails 112A and 116B, and PV module supportrails 112B and 116B discussed previously. It will be understood thatwhile FIGS. 7B and 7C show five crossbeams 108, mounting structuresconstructed according to the techniques described herein may be longer(i.e., having more crossbeams 108) or shorter (i.e., having fewercrossbeams).

FIG. 8 is a bottom perspective view of dual-tilt mounting structure 100with various water management features highlighted in accordance withvarious embodiments. In various embodiments, gaskets 800 are disposedbetween PV modules 114 that are installed in either landscapeorientation 202 or portrait orientation 130. This causes water 802 toflow down the angled top surface of mounting structure 100 and intogutter 302. From gutter 302, water is able to flow through pipe 304 andinto downspout 306. Thus, mounting structure 100 (and other dual-tiltmounting structure described herein) are able to shelter people andobjects underneath from precipitation and move water away. In someembodiments, mounting structure 100 may have integrated heating elements(e.g., heating elements in PV module support rails 112 and 116) thatprevent snow and ice from accumulating on PV modules 114.

Clamp

Referring now to FIGS. 9A-9H, various views of various embodiments ofclamp 500 are shown. FIG. 9A is a perspective view of a top portion 502and a bottom portion 504 of the clamp 500 shown in of FIGS. 5A, 6A, and7A in accordance with various embodiments. Top portion 502 is anL-shaped bracket having a first top plate 900 that defines a pair ofholes 904 and a second top plate 902 defines a pair of holes 906. Wheninstalled, first top plate 900 is configured to be adjacent tointermediate surface 722 of PV module support rails 112 and second topplate 902 is configured to lie on top flange 712 of purlin 110. In theembodiment shown in FIG. 9A, bottom portion 504 is a clamping jaw thatdefines a first portion 910 defining a rounded first top surface 912, asecond portion 914 defining a flat second top surface 915 with a hole916 configured to receive a clamping fastener 950, and a third portion918 defining a rounded third top surface 920. When installed, therounded first top surface 912 abuts top portion 502 and rounded thirdtop surface 920 abuts the underside of the top flange 740 of purlin 110.In various embodiments, the rounded first top surface 912 is configuredto breach one or more coatings on purlin 110 and establish a groundingpath between clamp 500 and purlin 119.

Referring now to FIG. 9B, a perspective view of a top portion 502 and analternate bottom portion 504A of an alternative clamp 500A is shown.Alternative bottom portion 504A is S-shaped with a first portion 932defining a hole 936 configured to receive clamping fastener 950 and asecond portion 924. When installed, the first portion 932 abuts topportion 502 and second portion 934 abuts the underside of the top flange740 of purlin 110. In the embodiment shown in FIG. 9A, a self-adhesivegrounding patch 700 may be inserted between second portion 934 and theunderside of top flange 740 of purlin 110. Alternatively, aself-adhesive grounding patch 700 may be inserted between second topplate 902 of top portion 502 and the top surface of top flange 740.

Referring now to FIGS. 9C-9H, various views of an installed clamp 500are shown. FIGS. 9C, 9E, and 9G are various views of clamp 500 installedwith the top portion 502 secured to an outer surface of a PV supportmodule support rail 112. FIGS. 9D, 9F, and 9H are various views of clamp500 installed with the top portion 502 secured to an inner surface of aPV support module support rail 112. As discussed herein, using clamp500, PV support module support rail 112 are able to be secured to themounting structure without welding and without having to pass fastenersthrough purlins 110.

Referring now to FIG. 9C, a side view of clamp 500 installed on amounting structure is shown. In FIG. 9C, clamp 500 is installed withfirst top plate 900 secured to an outer surface of a PV support modulesupport rail 112 by a pair of fasteners 940 (e.g., bolts) that extendthrough holes 905 and are secured by bolts 942 (see FIG. 9E). Second topplate 902 is secured to the top of top flange 740 of purlin 110. Twobottom portions 504 are disposed on the bottom side of top flange 740.Clamping fasteners 950 (e.g., a bolt) extends through holes 906 andholes 916 and is secured by nuts 952. Accordingly, tension on theclamping fasteners 950 secures second top plate 902 and bottom portions504 to purlin 110 such that top flange 740 is pinched between. FIG. 9Eis a cutaway side view showing clamp 500 installed on a mountingstructure as described in reference to FIG. 9C. Similarly, FIG. 9G is abottom perspective view showing clamp 500 installed on a mountingstructure as described in reference to FIG. 9C. As can be seen in FIG.9G, bottom portions 504 are disposed between the PV module support rail112 and the end of purlin 110 at a distance H from the end of purlin110.

Referring now to FIG. 9D, a side view of clamp 500 installed on amounting structure in an alternative manner is shown. In FIG. 9C, clamp500 is installed with first top plate 900 secured to an inner surface ofa PV support module support rail 112 by a pair of fasteners 940 (e.g.,bolts) that extend through holes 905 and are secured by bolts 942 (seeFIG. 9F). Thus, in contrast to FIGS. 9C, 9E, and 9G, top portion 502 isdisposed inside PV support module support rail 112 in some embodiments.Second top plate 902 is secured to the inside of bottom surface 724 ofPV support module support rail 112.

Two bottom portions 504 are disposed on the bottom side of top flange740. Clamping fasteners 950 (e.g., a bolt) extends through holes 906,holes through bottom surface 724 of PV support module support rail 112,and holes 916 and is secured by nuts 952. Accordingly, tension on theclamping fasteners 950 secures second top plate 902 and bottom portions504 to purlin 110 such that bottom surface 724 and top flange 740 ispinched between. FIG. 9F is a cutaway side view showing clamp 500installed on a mounting structure as described in reference to FIG. 9D.Similarly, FIG. 9H is a bottom perspective view showing clamp 500installed on a mounting structure as described in reference to FIG. 9D.As can be seen in FIG. 9H, bottom portions 504 are disposed a furtherdistance I from the end of purlin 110 compared to distance H in FIG. 9G.In the embodiment shown in FIGS. 9D, 9F, and 9H, bottom portions 504 aredisposed beneath PV support module support rail 112.

Self-Adhesive Grounding Patch

FIGS. 10A-10C are various views of the self-adhesive grounding patch 700in accordance with various embodiments. FIG. 10A is a plan view ofself-adhesive grounding patch 700. FIG. 10B is a side view ofself-adhesive grounding patch 700. FIG. 10C is a top perspective view ofself-adhesive grounding patch 700. In various embodiments, self-adhesivegrounding patch 700 includes a plate 1000 with an adhesive pad 1002disposed in the center. In various embodiments, plate 1000 is made ofmetal (e.g., stainless steel) and is a square with sides between 1(approximately 2.54 centimeters) and 5 inches (approximately 12.7centimeters) long. In various embodiments, adhesive pad 1002 is a peeland stick adhesive that is attached to plate 1000 during manufacturewith a peelable top sheet that is removed prior to installation asdiscussed herein. Cutouts 1004 are arranged around adhesive pad 1002 andare bent above and below to form spikes 1006. In various embodiments,eight cutouts 1004 and spikes 1006 are present and are arranged on thesides and corners of plate 1000 as shown in FIGS. 10A-10 , but otherarrangements can be used (e.g., more cutouts and spikes may be present).Compressive forces on self-adhesive grounding patch 700 cause the spikes1006 to penetrate coatings on components of the various mountingstructure discussed herein, enabling an electrical grounding path to beestablished between adjacent components. Such compressive forces, forexample, result from tension on the fasteners used to secure thestructural support components as discussed herein.

Method of Constructing Various Embodiments of Mounting Structure

FIG. 11 is flowchart illustrating an embodiment of a PV module supportstructure construction method 1100 in accordance with variousembodiments. In various embodiments, method 1100 is performed byconstruction personnel erecting a mounting structure (e.g., mountingstructure 100, 200, etc.) on a mounting surface 102. While method 1100proceeds upward from mounting surface 102, it will be understood thatthe sequence of these steps may be changed in various embodiments (e.g.,securing PV modules 114 to PV module support rails 112 on the ground andthen lifting the subassembly and installing it on purlins 110 asdiscussed herein).

A block 1102, a plurality of column foundations 104 are installed at amounting surface 102 such that column foundations 104 are partiallyembedded in mounting surface 102 and extend above mounting surface 102.At block 1104, columns 106 are coupled to the column foundations 104. Atblock 1106, a plurality of crossbeams 108 are coupled to the pluralityof columns 106. At block 1108, a plurality of purlins 110 are coupled tothe plurality of crossbeams 108. A first set of purlins 110 are coupledto first ends of the plurality of crossbeams 108 and a second set ofpurlins 110 are coupled to second ends of the plurality of crossbeams.At block 1110, a plurality of PV module support rails 112 are coupled tothe plurality of purlins 110. The plurality of PV module support rails112 includes a first PV module support rail 112, a second PV modulesupport rail 112, and a third PV module support rail 112. The second PVmodule support rail 112 is disposed between the first PV module supportrail 112 and the third PV module support rail 112. At block 1112, afirst set of PV modules 112 is coupled, in portrait orientation 130, tothe first PV module support rail 112 and the second PV module supportrail 112. At block 1114, a second set of PV modules 112 is coupled, inportrait orientation 130, to the second PV module support rail 112 andthe third PV module support rail 112.

As discussed herein, in various embodiments, clamp 500 is used toperform the actions of block 1110. Further, in various embodiments,self-adhesive grounding patches 700 may be installed between the coupledcomponents as part of performing the actions of blocks 1106, 1108,and/or 1110.

FIG. 12 is flowchart illustrating an embodiment of a PV module supportstructure construction method 1200 in accordance with variousembodiments. In various embodiments, method 1200 is performed byconstruction personnel erecting a mounting structure (e.g., mountingstructure 100, 200, etc.) on a mounting surface 102. While method 1100proceeds upward from mounting surface 102, it will be understood thatthe sequence of these steps may be changed in various embodiments (e.g.,securing PV modules 114 to PV module support rails 112 on the ground andthen lifting the subassembly and installing it on purlins 110 asdiscussed herein).

At block 1202, a plurality of column foundation 104 are installed at amounting surface 102. At block 1204, a plurality of columns 106 arecoupled to the column foundations 104. At block 1206, a plurality ofcrossbeams 108 are coupled to the plurality of columns 106. At block1208, a plurality of purlins 110 are coupled to the crossbeams 108 atends of the crossbeams 108. At block 1210, a plurality of PV modulesupport rails 112 are secured to purlins 110 using clamps 500.

As discussed herein, in various embodiments, PV modules 114 may beinstalled on top of PV module support rails 112 in portrait orientation130 or landscape orientation 202. Further, clamp 500 may be disposedoutside of PV module support rails 112 as shown in FIGS. 9C, 9E, and 9Gor partially inside of PV module support rails 112 as shown in FIGS. 9D,9F, and 9H. Further, in various embodiments, self-adhesive groundingpatches 700 may be installed between the coupled components as part ofperforming the actions of blocks 1206, 1208, 1210, and/or 1210.

Although specific embodiments have been described above, theseembodiments are not intended to limit the scope of the presentdisclosure, even where only a single embodiment is described withrespect to a particular feature. Examples of features provided in thedisclosure are intended to be illustrative rather than restrictiveunless stated otherwise. The above description is intended to cover suchalternatives, modifications, and equivalents as would be apparent to aperson skilled in the art having the benefit of this disclosure.

The scope of the present disclosure includes any feature or combinationof features disclosed herein (either explicitly or implicitly), or anygeneralization thereof, whether or not it mitigates any or all of theproblems addressed herein. Accordingly, new claims may be formulatedduring prosecution of this application (or an application claimingpriority thereto) to any such combination of features. In particular,with reference to the appended claims, features from dependent claimsmay be combined with those of the independent claims and features fromrespective independent claims may be combined in any appropriate mannerand not merely in the specific combinations enumerated in the appendedclaims.

What is claimed is:
 1. A system comprising: a plurality of columnsextending from a mounting surface along a first axis, wherein top endsof the plurality of columns are disposed above the mounting surface; aplurality of crossbeams coupled to the top ends of the plurality ofcolumns and extending along a second axis, wherein individual crossbeamsinclude a first end and an opposing second end; a plurality of purlinscoupled to the plurality of crossbeams and extending along a third axis,wherein a first set of purlins are coupled to the first ends of theplurality of crossbeams and a second set of purlins are coupled to thesecond ends of the plurality of crossbeams; a first plurality ofphotovoltaic (PV) module support rails extending along the second axisacross the plurality of purlins, wherein individual PV module supportrails include a bottom surface coupled to the plurality of purlins and atop surface defining a plurality of openings configured to acceptfasteners at least one individual PV module support rail continuouslyspanning across a distance along the second axis of a top surface of atleast one purlin coupled to the bottom surface of the at least oneindividual PV module support rail; and a plurality of rectangular PVmodules secured to the top surfaces of the first plurality of PV modulesupport rails by fasteners that extend through the rectangular PVmodules and the openings configured to accept fasteners; wherein theplurality of rectangular PV modules is disposed in portrait orientationin a first grid having columns extending along the second axis and rowsextending along the third axis; and wherein a first set of rectangularPV modules in a first column and second set of rectangular PV modules inan adjacent second column are secured to a top surface of a same PVmodule support rail disposed between the first column and the secondcolumn.
 2. The system of claim 1, wherein the columns, crossbeams,purlins, and PV module support rails are coated in a reflective coating.3. The system of claim 1, wherein a portion of the mounting surface iscoated in a reflective coating configured to reflect light toward therectangular PV modules.
 4. The system of claim 1, wherein therectangular PV modules are bifacial PV modules.
 5. The system of claim1, wherein the first grid defines a first plane; wherein the systemfurther comprises: a second plurality of PV module support rails coupledto the first plurality of PV module support rails and extending alongthe second axis; and a second plurality of rectangular PV modulessecured to top surfaces of the second plurality of PV module supportrails; wherein the second plurality of rectangular PV modules aredisposed in a portrait orientation in a second grid having columnsextending along the second axis and rows extending along the third axis,wherein the columns of the first grid and the second grid are alignedand the rows of the first grid and the second grid are parallel; andwherein the second grid defines a second plane that intersects with thefirst plane.
 6. The system of claim 1, wherein a plurality ofself-adhesive grounding patches is disposed between coupled columns andcrossbeams and between coupled crossbeams and purlins; and wherein anelectrical grounding path is established between the column, thecrossbeam, and the plurality of purlins.
 7. The system of claim 1,wherein the first plurality of PV module support rails are secured tothe plurality of purlins by respective clamps, wherein the clampsinclude: an L-shaped bracket having a first portion that is secured to agiven PV module support rail by one or more bracket fasteners and asecond portion coupled to a given purlin; one or more a clamping jawscoupled to a given top flange of the given purlin; and a clampingfastener extending through the second portion and the clamping jaw,wherein tension on the clamping fastener secures the second portion ofthe L-shaped bracket and the clamping jaw to the given purlin.
 8. Thesystem of claim 7, further comprising: a first set of self-adhesivegrounding patches disposed between the L-shaped bracket and the given PVmodule support rails; and a second set of self-adhesive groundingpatches disposed between the clamping jaw and the given purlin; whereinan electrical grounding path is established between the given PV modulesupport rail and the given purlin.
 9. The system of claim 1, wherein thepurlins are coupled to side surfaces of the first and second ends of thecrossbeams.